AN ABSTRACT OF THE THESIS OF in Daniel K. Melchior for the degree of Master of Science Mechanical Engineering presented on Title: March 12, 1980 The Effect of Geometric Orientation and Random Wind Conditions on Flat Plate Convection Rates Redacted for Privacy Abstract approved: Professor Milton B. Larson An experimental investigation has been performed to determine the forced convection heat transfer due to three-dimensional air flow over a flat plate as a function of angle of attack and free stream velocity. The experimental method employed a transient thermal technique and placed the convecting surface next to the exhaust port of an open circuit wind tunnel. The ratio of convecting surface width to wind tunnel nozzle width was 0.7, but insulating surfaces extended beyond the nozzle width. The flows evaluated ranged in Reynolds number from 32,000 to 140,000 and from zero to 90-degree angles of attack. The data indicated the probable existence of a turbulent boundary layer at zero and 45-degree angles of attack. Data collected for angles of attack of 30, 60, and 90 degrees demonstrate mostly laminar boundary layer flows and indicate a dependence of the Colburn i-factor upon angle of attack. The j-factor was determined to be proportional to the Reynolds number to the minus one-half power, as in previous work, and the multiplier varied between 0.876, as in a Pohlhausen equation corrected for unheated starting length, to 1.114 as predicted in wedge flow measurements performed by Eckert. The results are differ- ent from those of Sparrow and Tien, which indicate a single multiplier of 0.931 will provide solutions for all angles of attack between 25 and 90 degrees. The flow in this investigation is largely two- dimensional due to the physical arrangement of the apparatus, whereas the flow used by Sparrow and Tien was primarily three-dimensional. An analytical method was also developed which accounted for the random nature of the natural wind velocity distribution in the calculation of the time average convection film coefficient. The method uses the average velocity and the standard deviation of the velocity to provide an evaluation of the time average convection film coefficient. This was accomplished by transforming the defining convection relationship into a second order constant coefficient polynomial over a fixed range of velocities. The method was demonstrated on a statis- tical record of wind velocities measured on November 29 and 30, 1978 at the Oregon State University campus. The error created by using only the average velocity in calculating the time average convection film coefficient was determined to be 3.4%. The evaluation concludes that with present uncertainties in the convection film coefficient, the error introduced by ignoring the random nature of the wind is insignificant. 0 Copyright by Daniel K. Melchior February 29, 1980 All Rights Reserved THE EFFECT OF GEOMETRIC ORIENTATION AND RANDOM WIND CONDITIONS ON FLAT PLATE CONVECTION RATES by Daniel K. Melchior A THESIS submitted to Oregon State University in partial fulfillment of the requirements for the degree of Master of Science Commencement June 1980 APPROVED: Redacted for Privacy Professor of Mechanical Engineering in charge of major Redacted for Privacy Head of ical Engineering Depar ent Redacted for Privacy \Dean of Gr duate School Date thesis is presented 1 March 12, 1980 Typed by Donna Lee Norvell for Daniel K. Melchior ACKNOWLEDGEMENTS The author wishes to acknowledge the endless support, understanding, and encouragement of his wife, Pamela, and daughter, Kasee. TABLE OF CONTENTS I. II. INTRODUCTION DETERMINATION OF THE CONVECTION FILM COEFFICIENT BY EXPERIMENTAL METHODS 2.1 2.1.1 2.1.2 2.1.3 2.2 6 Experimental Methods Used Controlled heat transfer Transient heat transfer Mass transfer analogies steady state 6 7 11 13 Experimental Apparatus 2.2.1 13 Individual component design Fan Plate Insulation block 2.2.2 2.3 2.3.2 2.3.3 2.4.3 Heating and stabilizing plate temperature. Measurement of temperature and time Measurement of air velocity . Mathematical model and analysis Experimental data Uncertainty analysis Results and Comparison with Previous Work 2.5.1 III. 23 Data Reduction 2.4.1 2.4.2 2.5 20 Experimental Procedure 2.3.1 2.4 Means of orientation System integration Applicability to solar collectors 23 25 26 29 29 33 33 35 45 EXTENDING THE CONVECTION FILM COEFFICIENT DETERMINED FOR CONSTANT VELOCITIES TO RANDOM VELOCITY DISTRIBUTIONS, AN APPROXIMATE ANALYTICAL APPROACH 3.1 Evaluating the Covection Film Coefficient Using_ the Average and the Standard Deviation of the Wind Velocity 49 3.2 IV. Examination of the Error Introduced by Using the Average Wind Velocity to Predict the Average Convection Film Coefficient 55 CONCLUSIONS 4.1 4.2 4.3 Dependence of the Convection Film Coefficient Upon Angle of Attack 61 Random Wind Velocities and the Average Convection Film Coefficient 63 Future Research 65 BIBLIOGRAPHY APPENDICES Appendix A -- Nomenclature Appendix B -- Determination of Stable Temperature Decay Region (Sphere Tests) Appendix C -- Determination of Insulation Losses. Appendix D -- Tabulated Data and Results Appendix E -- Tables, Charts, and Graphs 68 70 . 74 79 80 LIST OF ILLUSTRATIONS Page Figure 1 Measured thermal conductance of insulation block. assembly 10 . 2 Wind tunnel design 15 3 Wind tunnel sketch 16 4 Exit port nozzle design 17 5 Insulation block assembly (cut-away view) 19 6 System arrangement 21 7 Test configuration. 22 8 Method used to warm aluminum plate 24 9 Typical time/temperature profile 27 10 System energy balance 30 11 Results of previous zero degree angle of attack studies 36 12 Zero degree angle of attack data 38 13 30-degree angle of attack data 40 14 45-degree angle of attack data 41 15 60-degree angle of attack data 43 16 90-degree angle of attack data 44 17 Measured j-factor dependence upon angle of attack 18 Agreement between interpolating polynomial and governing equation (3-23) 19 20 Measured temperature dependence of the flat plate convection film coefficient Measured temperature dependence of the sphere convection film coefficient . . 46 57 71 72 List of Illustrations, continued Page Figure Total insulation block assembly thermal conductance as a function of plate temperature 77 22 Fan performance 83 23 Wind velocity measurement uncertainty 86 Design constraints for wind tunnel 14 Values of parameters used for data reduction with equation (2-15) 34 3 Values used for parameters in equation (3-22) 55 4 Selected points 56 5 Errors introduced by ignoring statistical information. 58 6 Measured decay times and calculated conductance losses 75 7 Total measured conduction losses through insulation block assembly 76 8 Measured data 79 9 Calculated j-factors 80 10 Biot numbers for various materials 82 11 Properties of the aluminum plate 84 12 Properties of insulation block material 85 13 Wind velocity data 87 21 Table 1 2 THE EFFECT OF GEOMETRIC ORIENTATION AND RANDOM WIND CONDITIONS ON FLAT PLATE CONVECTION RATES SECTION I INTRODUCTION 2 INTRODUCTION The challenge of meeting our nation's growing energy demands requires the prudent use of our energy resources. Our increasing re- quirements coupled with ever-decreasing supplies of useful energy and the associated economic inflation dictates tighter engineering tolerances for our energy using and producing systems. These tighter tolerances are required as our need for more optimal designs increases. Large safety factors built into the space heating systems in most buildings, which account for unpredictable or unknown energy losses, reduce the overall system efficiency. Solar collector arrays are over- sized to account for unknown top losses due to ambient wind effects. These are just two examples of many engineering systems which are oversized because of imprecise knowledge of ambient effects on surface heat transfer. Forced convection heat transfer has been the subject of much research throughout modern history. However, little of the research is directly applicable to modern flat plate solar collectors. Early work performed by Dr. Ing-Walter Jurges [1] of Germany in 1924 has provided the basis for the wind-dependent convection film coefficient predicting equation used in most of the current solar collector top loss calculations. The validity of using Jurges' equa2 tion (1-1), where his expressed in w/m °C and V is in m/s, h w = 5.7 + 3.8V 3 for solar collector top loss calculations is questionable. The in- vestigation evaluated only a moving air stream parallel to a flat plate, and ignores the dependence of the convection film coefficient upon the distance from the leading edge. These questions prompted E. M. Sparrow and K. K. Tien [2][3] to undertake an investigation which evaluated the effect of various angles of attack upon the convection film coefficient. Their investigation used a mass sublimation technique to infer the heat transfer rate. The apparatus consisted of a 7.6 cm square plate suspended at various angles of attack within a wind tunnel. The maximum ratio of wind tunnel width to plate width was 0.25 and blockage was determined to be negligible. The air flow was relatively unrestricted and angles of attack between 25 and 90 degrees were investigated for Reynolds numbers between 20,000 and 100,000. The results of their work, shown in equation (1-2), demon- strated virtual independence of the convection film coefficient, as reflected in the Colburn j-factor, with respect to angle of attack. (1-2) j = .931 Re-1/2 Recent work by R. G. Sam, R. C. Lessmann, and F. L. Test [4] from the University of Rhode Island on the pressure distribution on the surface of a rectangular prism for various angles of attack and wind velocity currents investigated laminar and turbulent twodimensional flow characteristics. The report provided information as a part of an investigation into convective film coefficients for 4 inclined surfaces as a function of wind currents. The heat transfer work, sponsored by the National Science Foundation, is currently in progress. The present investigation provides information which bridges the earlier work of Jurges and the recent work of Sparrow and Tien. The method used consisted of a transient thermal technique in which a flat plate of known specific heat was warmed and allowed to cool under controlled ambient conditions. The physical apparatus used a 30.4 cm square plate mounted in an insulation block and oriented at various angles of attack relative to the exhaust port of an open circuit wind tunnel. width was 0.7, The ratio of convecting surface width to nozzle while the ratio of the insulated surface width to the nozzle width was 1.35. The wind velocities ranged between 1.5 and 7.6 m/s (5 to 25 ft/sec) which correspond to a Reynolds number range from 32,000 to 140,000. and 90 degrees. Angles of attack ranged from zero 5 Section II DETERMINATION OF THE CONVECTION FILM COEFFICIENT BY EXPERIMENTAL METHODS 6 2.1 EXPERIMENTAL METHODS USED The convection film coefficient can be experimentally measured in many different ways. transport phenomenon. Most of the techniques rely on two different The first group relies on direct measurement of heat transfer and may use steady state systems or transient techniques. The second group relies on the measurement of mass transfer as an indirect measurement of heat transfer using the analogy between mass and heat transfer to infer the convection film coefficient. Various advantages and disadvantages of both measurement techniques will be discussed in the following section along with experimental methods which were found to reduce the error associated with the direct transient heat transfer technique employed in this investigation. 2.1.1 Controlled Heat TransferSteady State A steady state controlled heat transfer method was used by W. Jurges [1] in 1924. This technique involves the establishment of a uniform heat flux interface at the heat transfer surface. The energy applied to the plate in the form of electric resistance heating was controlled to maintain a 30°C temperature difference between the plate surface temperature and the ambient while exposed to a steady and established wind velocity relative to the plate. Losses through the in- sulation block were measured and deducted from the total energy supplied to the system to determine the rate at which energy was convected from the surface. This method is obviously the most direct and 7 with proper experimental controls should provide very accurate results. It should be noted, however, that the experiment performed by Jurges only examined conditions of zero degree angle of attack. This method would be ideal for measuring the effect of angle of attack, and with the use of modern strip heaters and insulation materials should provide excellent results. A major disadvantage of this technique is the length of time required to establish a steady state convection situation. The stabilizing time can be decreased by designing for a small thermal mass and automatic temperature control. 2.1.2 Transient Heat Transfer The transient heat transfer method, such as that used in this investigation, consists of heating a material of a known specific heat to a high temperature and then allowing the material to cool to ambient temperature under controlled conditions. Measurement of the rate of temperature decay will yield the convection film coefficient directly in terms of heat transfer for the specific conditions experienced during the temperature decay. While this method is the most direct and the easiest to implement, it does have characteristics which limit the accuracy which can be achieved. Meaningful results can only be achieved if the entire body undergoing a thermal decay is at a uniform or nearly uniform temperature. The mathematical complexi- ties introduced by allowing for a nonuniform temperature distribution throughout the body are impractical to implement. However, a nearly uniform temperature throughout the body can be achieved if the 8 conduction resistance in the solid is much less than the convection resistance at the surface of the body. This ratio has been given the name of the Biot number (Bi) and is a quantitative representation of the degree of temperature uniformity achievable. General practice has indicated that an error of less than 5% in uniformity of temperature is achieved for Biot number less than 0.1. The mathematical expression which describes the Biot number is shown in equation (2-1) where the convection film coefficient and the thermal conductivity of the material are represented by h and k, respectively. Bi = kQ (2 -1 ) The characteristic length Q is often found by dividing the volume of the body by the convecting surface area, which for a flat plate with Care must be taken to one exposed surface will yield the thickness. express h, k, and R. in the same system of units. The Biot numbers for several materials are tabulated in Appendix E for the maximum ex2 pected convection film coefficient of 19 w/m °C at 7.6 m/s wind velocity and a plate thickness of 0.406 cm. search was 7075 T6 Alclad The material used in this re- aluminum plate. The present results indicate that only a specific range of temperature difference between plate and ambient temperature may be used to evaluate the convection film coefficient. Large temperature dif- ferences between the plate and ambient result in greater thermal losses through the supporting insulating materials. When the plate 9 temperature approaches ambient, very small temperature differences between where the thermocouple is located and the surface can cause large deviations in the derived convection film coefficient. Direct heat transfer measurement techniques suffer the common problem of unknown or uncontrollable thermal losses through means other than the forced convection under investigation. These losses can be due to conduction through the insulation material or changes in the internal energy of the insulation. Conduction losses through the in- sulated surfaces may be dependent upon the temperature of the plate due to possible temperature-dependent characteristics of the insulation. A method was developed which allowed an experimental approximation of the conduction losses as a function of the plate temperature using the same transient thermal technique which was used to determine the convection film coefficient. The procedure is explained in detail in Appendix C and the results are shown in Figure 1 and Appendix C. The experimenter must be careful to use only data obtained when the assumption of one homogenous temperature is sufficiently accurate. The experimental determination of the temperature regions in which the assumption is sufficiently accurate is explained in detail in Appendix B. 0.13 0.08 (0.15) Apparatus Conductance WPC (BTU/hr°F) 0.05 (0.10) (110)43 (130 54 (150)66 (170)78 Temperature(°F) °C 190 88 MEASURED THERMAL CONDUCTANCE OF INSULATION BLOCK ASSEMBLY FIGURE 1 210)99 11 2.1.3 Mass Transfer Analogies The mass transfer technique employed by Sparrow and Tien [2][3] involved the measurement of the sublimation of naphthalene from a 7.62 cm (3 in) square plate oriented at various angles of attack and yaw within a low-velocity, low-turbulence wind tunnel. According to Sparrow, the average mass transfer is related to the average heat transfer in such a way that their associated j-factors are equal. The j-factor for mass transfer and heat transfer are shown in equation (2-2) and equation (2-3), respectively. ent, k', is defined in equation (2-4). The mass transfer coefficiAppendix A defines the nomen- clature used throughout this paper. (k7u.)Sc2/3 j = j = StPr 2/3 (mass transfer) (2-2) (heat transfer) (2-3) (2-4) k' = M(pnw - pno,) Mass transfer methods can yield greater precision than direct heat transfer measurement techniques because surfaces which are ideally abiabatic in the heat transfer problem may be accurately represented by surfaces composed of a nonsubliming material. The integrated aver- age mass transfer rate is directly obtained through the calculation of the mass sublimed in a given time period. Such a calculation only required the difference between the starting and ending mass and the elapsed time. The greatest uncertainty results from the mass 12 sublimed during the time required to set up and dismount the sample. It is important to note that the accuracy of any mass transfer method is dependent upon the accuracy of the mass to heat transfer analogy. 13 2.2 EXPERIMENTAL APPARATUS The apparatus used in the experimental determination of the convection film coefficient consisted of a low-velocity wind tunnel, a square aluminum plate mounted in an insulation block with a means for orientation to predetermined angles relative to the wind tunnel air stream, and an Esterline Angus PD 2064 Data Logger. The various com- ponents will be described in detail and a description of the integrated system layout will follow. 2.2.1 Individual Component Design The desired properties of the wind source are described in Table 3. The design conceived to meet the criteria listed in Table 1 is shown in Figure 2 and Figure 3. The wind tunnel consisted of two 50.8 cm (20 in) axial fans along a common axis. Each fan had three individual speed settings as well as an easily damped intake port allowing for a wide range of exit velocities. The performance of the fan as a function of exit area is shown in Appendix E. of 1096 cm 2 An exit area (170 in2) was found to offer the best performance and also provide a uniform velocity air stream over the test plate. The ex- haust port nozzle was designed to provide a gradual transition from the circular pipe to the square exit area. Care was taken to make the convergence gradual and to provide a small straightening section in the exhaust grill to correct for any distortion due to the circular to square transition. The exhaust port was designed such that the square exit area could be rotated to any desired angle if future tests 14 would require a different configuration. The design for the exhaust port nozzle is shown in Figure 4. TABLE 1 DESIGN CONSTRAINTS FOR WIND TUNNEL 1. Velocity variable from 1.5 to 7.6 m/s (5 to 25 ft/sec) 2. Provide a constant and predictable velocity at the exhaust port which was uniform throughout the cross-section (square cross-section). 3. Have a large enough exit area such that the wind velocity would be uniform over the surface of the plate. 4. Provide a wind source which could be.external to the heat transfer surface and allow unrestricted three-dimensional flow above the heat transfer surface. Testing of the velocity distribution over the cross-section of the exit port indicated considerable spiral of the air stream in the pipe section between the fans and the exit port. This condition was corrected by installing 30.50 cm x 10 cm diameter (12 in x 4 in diameter) tubes just behind the diffuser section in the large pipe area as' indicated in Figure 2. Velocity distribution tests after installation of the straightening tubes showed a maximum variation in exit port velocity of 2% over the cross-section. This variation was thought to be the best which could be achieved with the funds available and was consistent with accuracy expected on a system level. intensity in the exit air stream was not determined. The turbulence 1.98 (78.00) Straightening Section Flow Stabilization Section OOOOOOO Dimensions in (in) m WIND TUNNEL DESIGN FIGURE 2 Exit Nozzle Port WIND TUNNEL SKETCH FIGURE 3 0.5(19.75)Dia. 0.25 (10.00) (17000) 0.43 (7.00) ____ 0.178 m Dimensions in (in) EXHAUST PORT NOZZLE DESIGN FIGURE 4 or-43.00) 0.076 18 The source of thermal energy in the experimental apparatus was a 30.48 x 30.48 x .406 cm (12 x 12 x .160 in) aluminum plate. perties of the plate material are specified in Appendix E. The proThe mass of the plate was determined by weighing the plate to within one-half gram. Holes for thermocouples were drilled into the rear surface of the plate to within 0.1 cm (.040 in) of the front surface. This ar- rangement left a 13.97 cm (5.5 in) border of insulation around the square aluminum plate and allowed the surface of the aluminum plate to be flush with the surface of the aluminum foil-faced insulation material. A mounting plate which would accept the threaded stud of a camera tripod was attached to the adhesive. back of the insulation block with contact The resulting assembly allowed the convenient adjustment of the insulation block and the associated heat transfer surface to any desired angle. Prior to the final installation of the aluminum plate into the insulation block, a small hole was drilled through the insulation and mounting plate to allow the thermocouple wires to be fed Once the aluminum plate was through the back of the insulation block. installed in the insulation block, the interface between the edge of the aluminum plate and the insulation block was taped with hightemperature tape to assure a smooth aerodynamic transition between The final assembly allowed the plate and the foil-faced insulation. orientation of the exposed surface of the plate to any desired angle. The construction of the aluminum plate and the installation into the insulation block are shown in Figure 5. The specified insulative properties of the insulation material and the measured insulation block conductance are shown in Appendix E. Convecting Surface (aluminum plate) Thermocouple locations Insulation Aluminum Mounting plate Camera tripod mounting hole Thermocouple wire access hole INSULATION BLOCK ASSEMBLY (CUTAWAY VIEW) FIGURE 5 tO 20 2.2.2 System Integration The integrated system is shown in Figure 6. The purpose of the low-velocity wind tunnel is to provide a steady horizontal air flow over the convecting surface. The surface can be adjusted to any desired angle of impingement through the operation of the camera tripod mount. Once the air flow leaves the exhaust port of the wind tunnel, the stream is free to interact with the heat transfer surface in a threedimensional manner and is restricted only by the interaction with the insulation block. Figure 7 shows the test configurations used. This arrangement should provide realistic data which are applicable to many real-life engineering situations such as solar collectors, building walls, and roofs. Convecting Surface a.) N N Fan Wind Tunnel 0 #2 Insulation Block Camera Tripod Table SYSTEM ARRANGEMENT FIGURE 6 Fan #1 Nozzle Straightening Tubes Air Angle of Attack Flow TEST CONFIGURATIONS FIGURE 7 23 2.3 EXPERIMENTAL PROCEDURE The experimental procedure used in a transient heat transfer method, such as the one employed in this investigation, must be carefully controlled to assure maximum accuracy. The following section covers the experimental techniques developed throughout the course of this investigation which enhanced the accuracy and repeatability of the data collected. Three main areas which require special attention are heating and stabilizing the aluminum plate temperature, measurement of the decaying temperature and associated times, and the accurate measurement of the air velocity. 2.3.1 Heating and Stabilizing Plate Temperature The mathematical model used to analyze the data requires the assumption of a uniform plate temperature. Any deviation from a uni- form plate temperature will introduce error into the results. There- fore, each data run must start from the most uniform temperature possible. The heating arrangement consisted of a temperature-controlled hot plate with a cast aluminum top approximately 15 cm (6 in) square which was inverted in the middle of the aluminum plate as shown in Figure 8. The perimeter of the aluminum plate which was not in direct contact with the hot plate surface was insulated with newsprint during the warm-up period to reduce the heat loss and allow a more uniform plate temperature to develop. The center plate temperature was held at approximately 93°C (200°F) while the outer perimeter temperature was 24 Perimeter of Convecting surface insulated during warm up period Temperature controlled electric resistance hot plate inverted on convecting surface Insulation Block Assembly METHOD USED TO WARM ALUMINUM PLATE FIGURE 8 25 monitored with the data logger. Once the outer perimeter reached equi- librium with the inner plate temperature, the hot plate was removed and the entire insulation block assembly was covered with a 58 x 58 x 5 cm block of polyurethane foam insulation. The plate was allowed to cool to approximately 77°C (170°F) to further stabilize and assure a uniform plate temperature. A maximum deviation of 2°C between plate center and plate edge was allowed with a common deviation of less than 1°C. Once a stable plate temperature of 77°C had been reached, the heat transfer surface was placed in the air stream which was flowing from the wind tunnel at a predetermined velocity. The desired angle of im- pingement was set with the tripod mount and the data logger was programmed to read the temperature of the plate and the corresponding time at 15 to 60-second intervals depending on the rate of temperature decay. The temperature of the plate was monitored between 77° and 27°C, although the temperature region between 77° and 49°C was not used for data purposes due to the inconstant apparatus conductance as was determined in Appendix C. Plate temperatures below 35°C were avoided due to measurement inaccuracies as was determined in Appendix B. 2.3.2 Measurement of Temperature and Time The temperature and time measurements were made with an Esterline Angus Model PD 2064 programmable data logger. The data logger accepts thermocouple signals as an input and provides the temperatures and associated times as output. Both visual and hard copy output were 26 provided. The operation procedure consisted of defining a start time and the interval between measurements. vided automatically. All other functions are pro- The final output is a very accurate profile of temperature of the plate and the associated times. Data reduction requires the time for the temperature to decrease from 49°to 38°C and the specific conditions of the test. Figure 9 illustrates a typical time/temperature profile along with the associated upper and lower temperature limits used to bracket the region of data collection. 2.3.3 Measurement of Air Velocity Measurements of the air velocity were made with a pitot tube attached to a precision micromanometer, and cross-checked with a 10 cm diameter averaging vane-type anemometer. The velocity was measured 2.5 cm (1 in) above and parallel with the leading edge of the aluminum plate, while the insulation block was horizontal and touching the bottom of the exit nozzle. This was outside the boundary layer and was thought to be a good representation of the free stream velocity. Velocity readings were taken across the plate width and averaged. The same method was used to determine the exit velocity for all orientations of the plate relative to the air flow. Pitot tube velocity measurements of the air stream velocity were performed with the insulation block oriented at each angle of attack and compared to the horizontal measurements to assure that no blockage of the exit port was measurable. The measurement uncertainty ranged from ±.1 to 27 78 (170) \ a) 'S 4C-CS.' 54 - (130) a) , F 4s1t3_ a CUE t a) all_ 1 e.rops.r.a 1 u.r...e._ ____ . 43 7_ (110) \ 32 \-- N (90) '' .--. 21 (70) 0 5 10 15 Time in minutes TYPICAL TIME/TEMPERATURE PROFILE FIGURE 9 20 28 ±.3 ft/sec, with the greatest uncertainty encountered at lower velocities. The uncertainty of the velocity measurement as a function of velocity is shown in Appendix E. 29 2.4 DATA REDUCTION The method of analysis used requires the assumption of a uniform temperature throughout the plate. The association between the accuracy of this assumption and the Biot number was explained in Section 2.1. Due to the low value of the Biot number for the system employed, the variation of temperature throughout the plate should be small. The data taken demonstrated that the plate was not at the same temperature everywhere, but tended to be cooler at the leading edge and warmer at the trailing edge. The temperature was measured 2.5 cm from the edge and at the centerline of the plate. The data showed an overall plate deviation of approximately 2% at the highest convection rates with smaller variations for lower convection rates. The temperature at the geometric center of the plate was taken as the most representative of the overall temperature in all subsequent data reduction. 2.4.1 Mathematical Model and Analysis The nature of the system involved can be viewed as a simple energy balance, in which the internal energy change of the body is equal to the energy lost to the environment. Consider an arbitrary volume represented in Figure 10 where the losses due to radiation are ignored because it accounts for no more than 0.5% of the total energy loss. 30 The internal energy change per unit time is represented by equation (2-5). pvc dT internal energy change (2-5) TIT The convection and conduction losses can be represented by equation (2-6), (H + K(T))(T - T.) = energy losses (2-6) where K(T) represents the temperature-dependent conduction loss through the insulation and H represents the convection loss from the exposed surface. If K(T) can be approximated by a constant over a given tem- perature range, then K(T) can be replaced by K which merely represents 31 the total energy loss due to conduction through the insulation. Equating equation (2-5) and equation (2-6) results in the differential equation (2-7), which describes the energy balance for the system. atpvc = (H + K) (T - Ted dt (2-7) Equation (2-7) can be rearranged to the form of equation (2-8) (H+K)dt pvc dT (T-Tm) (2-8) Integrating both sides of equation (2-8) and evaluating the arbitrary integration constant with the boundary condition that the temperature at some arbitrary start time, t = 0, is equal to a constant T., results in equations (2-9) and (2-10). Substitution of the constant determined in equation (2-10) into equation (2-9) yields equation (2-11). r (H+K) 0-7c t "r ul , tn(T-T.) = @ t = 0, C1= 9n (To - T.) bl(T- T ) = (H+K) t + Ln(To - T.) pvc (2-9) (2-10) (2-11) Equation (2-11) can be rearranged into a more useful form which is shown in equation (2-12). The convection heat loss represented by H can be replaced by the average convection film coefficient times the 32 exposed surface area giving equation (2-12) pvc - IT-Too kn= to 1 K To-Ted A (2-12) The resulting convection film coefficient can be nondimensionalized by multiplying by the plate length L and dividing by the thermal conductivity of the moving air stream K'. This yields the average Nusselt number as shown in equation (2-13). 1 K1 1'71j T.,-Toj Al mc "u Tit L K' 171 to [ T-To, (2-13) The results can also be expressed in terms of the Colburn j-factor as defined for heat transfer by equation (2-14) Nu j = StPr2/3 (2-14) RePrl /3 Using the appropriate substitutions for the Reynolds, Prandtl and Nusselt numbers results in equation (2-15), which was used for the reduction of the data collected. Pr I 2/3 p c I [ me to I T -T. 1 To-T. j K (2-15) j The Reynolds number which characterizes the flow was evaluated at the length of the aluminum plate, 0.3048 m (1 ft), for all cases. 33 The air velocity ranged from 1.7 to 7.6 m/s (5.6 to 25 ft/sec) which corresponded to a Reynolds number range of 31,900 to 140,000. Table 2 lists the values for all the parameters used to evaluate the appropriate j-factor in equation (2-15). 2.4.2 Experimental Data Each data run resulted in a recorded temperature decay profile under constant ambient conditions from 77° to 27°C (170° to 80°F). Greatest accuracy was achieved by picking the desired start temperature in the region of 49°C (120°F) and a stop temperature in the region of 38°C (100°F). The time associated with these two temperature measure- ments is the time required for the aluminum plate to decrease in temperature from approximately 49° to 38°C (120° to 100°F). Appendix D lists the start, stop, and ambient temperature; with the associated decay time and the calculated j-factors for the orientation and wind velocity listed. The data were recorded in °F, feet per second, and minutes for temperature, wind velocity, and time, respectively. 2.4.3 Uncertainty Analysis An uncertainty analysis was performed on equation (2-16) with the worst case uncertainty of the various parameters as stated in Table 2. The temperature and air velocity measurements proved to be the largest sources of error, indicating a maximum j-factor uncertainty of .00024, which corresponds to a maximum uncertainty of 4.5%. 34 TABLE 2 VALUES OF PARAMETERS USED FOR DATA REDUCTION WITH EQUATION (2-15) Parameter Name Pr Prandtl # .7055 P' density of air .07226 Uncertainty Units Value ± 0.0015 - lbm/ft ± 0.00005 3 ± 0.5 174.5 P density of aluminum c specific heat of aluminum .225 Btu/lbm°F ± 0.0005 c' specific heat of air .2403 Btu/lbm°F ± 0.0001 u. free stream air velocity measured ± 0.3 max ft/sec 2.288 ibm measured minutes ± 0.002 m mass of aluminum plate t time A area of aluminum plate To temperature measured °F ± .05 T. start temperature measured °F ± .05 T ambient temperature measured °F ± .05 K thermal conduction loss (measured) Btu ± .001 ft 1 0.1030 ± 0.00016 2 negligible hr °F _ . 35 2.5 RESULTS AND COMPARISON WITH PREVIOUS WORK The convection film coefficient, as reflected to the Colburn jfactor is dependent upon the type of flow exhibited in the boundary layer. A change in the boundary layer from laminar to turbulent is characterized by a decrease in slope in the j-factor curve. Accord- ing to Kays [5], the j-factor associated with laminar flow will be dependent upon the Reynolds number to the -0.5 power, while that associated with turbulent flow will be dependent upon the Reynolds number to the -0.2 power. Transition flows will probably have a slope which is bounded by these two values. Figure 11 shows the results which were provided by Jurges [1] and associated calculated flat plate curves representing a laminar and a turbulent boundary layer based on correlations presented by Kays [5]. Both flat plate curves have been corrected to account for the effects of approximately 0.35 m of unheated starting length associated with Jurges experimental apparatus. The j-factor for laminar flow including the unheated starting length is shown in equation (2-16). in Kays. This was derived from Pohlhausen solution described The contribution due to the unheated starting length in- creased the j-factor by approximately 47%. (2-16) j = .976 Re-1/2 Equation (2-17) derived from Kays' work describes the j-factor associated with a turbulent boundary layer which was increased by approximately 10% due to the unheated starting length. 0.007 , Jurges ..,, 0.006 * Flat Plate-'' 0.005 ,,,, .. * Flat Plate 0.004 ,,, ,,,,,,,, ,,,,, . ,,,,, Turbulent J 444,,,,,,, ,,,,,, '44.1%% 0.003 *corrected for unheated starting length 0,002 20,000 30,000 40,000 60,000 80,000 Reynolds Number 100,000 RESULTS OF PREVIOUS ZERO DEGREE ANGLE OF ATTACK STUDIES Figure 11 150,000 200,000 37 (2-17) j = .0368 Re-0'2 The relationship between Jurges results and the calculated laminar and turbulent flow predictions shown in Figure 11 seem to indicate that the flow experienced by Jurges was laminar at the lower Reynolds numbers and became progressively more turbulent at higher Reynolds numbers. The larger values for the j-factors in Jurges work could be attributed to unaccounted thermal losses or consistent measurement error. Figure 12 compares the Jurges results and the zero-degree angle of attack data measured by the author. The same approach used to develop equation (2-17) was used to develop a turbulent flow j-factor equation which takes into account the effect of the unheated starting length imposed by the insulated border in the present study. This is shown in equation (2-18) and is plotted in Figure 12 for comparison. (2-18) j = .0351 Re-0'2 The slope of the best fit line through the data is evidence of a high degree of turbulence, and was probably due to the effect of the leading corner of the insulation block which protruded approximately 1.2 cm into the air stream. This arrangement was used to minimize any blockage of the air stream over the plate due to tubular flow straighteners in the exhaust port nozzle. Transition from a laminar to turbulent boundary layer due to steps in flow path has been confirmed by Sam, Lessmann, and Test [4]. 0.007 Jurges 0.006 *Flat Plate 0.005 .... , /Turbulent .,,,,,,,,, _ .,, 0.004 ,........_ -- ...... -- . , ,. ,,,, -.......... .... 0.003 -, , -........,,..,, *corrected for unheated starting length 0.002 20,000 0,000 40,000 60,000 80,000 Reynolds Number 100 000 150,000 200,000 ZERO DEGREE ANGLE OF ATTACK DATA CO Figure 12 39 The data which are plotted in Figure 13 for a 30-degree angle of attack indicate a nearly laminar flow. The best fit line does show a small tendency to rotate towards a slope which indicates turbulence was present. (Turbulence will tend to lower the j-factor at lower Reynolds numbers and raise it at higher Reynolds numbers for the range of 30-degree data.) The actual turbulence intensity of The the wind tunnel was not measured and probably is fairly large. tendency toward laminar flow confirms results of Sam [4] which indicate that angles of attack above 30° tend to stabilize the flow. The disagreement evident at lower Reynolds numbers between the 30° degree data and the Pohlhausen solution shown in equation (2-19) and plotted in Figure 13 is probably due to turbulence. = .876 Re-1/2 (2-19) It is the author's opinion that the Pohlhausen flat plate solution, which has been corrected for unheated starting length, represents the j-factor associated with a 30-degree angle of attack for the present data. The 45-degree angle of attack data plotted in Figure 14 appears to be the result of a turbulent boundary layer, as evidenced by the slope of the j-factor curve. According to Sam [4] the increasing angle of attack should continue to reinforce the laminar nature of the flow. The increased turbulence compared with the 30-degree angle of attack data indicates that a possible interaction between wind tunnel turbulence and angle of attack existed in the region of 0.007 \ \ \ \ \ \ \ \ \ \ \ \ \\ 0.006 %\\*\ Sparrow \*\ 8' 0.005 \\*\\ *F-1-a t P teLamin a 0.004 ..... r - --:*-,-...... 3 \N\*\\ \\ 0.003 *\u,.. .\\t,4,,,;,,,,,,, *corrected for unheated starti length 0.002 20,000 30,000 40,000 80,000 60,000 Reynolds Number 100,000 30-DEGREE ANGLE OF ATTACK DATA Figure 13 0.007 %4k 0.006 0x, A%\,, A\`'\v \ \ \\ 0.005 0.004 Spa-row & Tien --\\\\\ \\\\\\\\ .* 0004 Flat Plate Turbulent h %%%%%%%%% \\1*- 3 %N%., ''"k... -. %%%%%%% .--,....... 0.003 '\\ 0.002 20,000 30,000 40,000 60,000 80,000 Reynolds Number 100,000 45-DEGREE ANGLE OF ATTACK DATA Figure 14 150,000 200,000 42 45 degrees, which overpowered the stabilizing effects of the larger attack angle. Because Sparrow and Tien's results exhibit a laminar flow, the turbulence data taken at 45 degrees is not directly comparable. Figures 15 and 16 provide the data which are the most closely related to the work of Sparrow and Tien. The slope of the data indi- cates that a very nearly laminar flow situation existed. This con- firms the predictions of Sam [4] concerning the stabilizing of laminar flow at high angles of attack. The data provided in Figure 16 for a 90-degree angle of attack can be directly compared to a laminar boundary layer wedge problem in which u. = cxm as described in Kays [5]. In this situation, the j-factor equation is derived to be equation (2-20). (2-20) j = 1.114 Re-1/2 Equation (2-19) is plotted in Figure 16 and indicates good agreement with the experimental results determined here. Figures 15 and 16 indicate a dependence of j-factor upon angle of attack which was not observed by Sparrow and Tien. It is the author's opinion that these discrepancies can be attributed to the different flow geometries which existed in the experimental arrangement. Sparrow and Tien measured the j-factor for a 7.6 cm square plate suspended in a large low-turbulence wind tunnel. Thus, the flow by the test specimen was relatively unrestricted. In con- trast, the system employed here consisted of a convecting surface 30.48 cm square surrounded by a 14 cm border, located external to a 0.007 0.006 li \\ \\ \\ \ \ \ \ \ ... 0.005 . ---, . .., Sparrow & Tien ---1- // 0.004 .. .. .. , . . -- .. ., ., 3 . / . .. ...,. */ 0.003 ... yyiyyy/ 0.002 20,000 30,000 40,000 60,000 80,000 Reynolds Number 100,000 60-DEGREE ANGLE OF ATTACK DATA Figure 15 150,000 200,000 1111110111 11111111111111111111111111 111111111111 ,1111 Nunn sczs -v\e\ 11111111111111111111101111111 10111 011001 1111110= 11111111111M O o 45 43 x 25 cm wind tunnel exhaust port. Because the total dimensions of the insulation block exceeded the width of the wind tunnel exit port, largely two-dimensional flow around the test surface was probable at all angles of attack except 90 degrees. Figure 17 summarizes the results for each angle of attack from zero to 90 degrees. The curves which represent zero and 45 degrees appear to exhibit turbulence due to their slope and cannot be directto the laminar flow work of Sparrow and Tien. ly compared The mea- sured difference between the zero and 45-degree data is small and could, within experimental error, indicate an independence of the turbulent flow j-factor upon angle of attack (between zero and 45 degrees only). The 30-degree data do not substantiate this conclu- sion because the flow experienced at that angle appeared to be laminar. The data shown in Figure 17 corresponding to angles of attack of 30, 60 and 90 degrees, which exhibited laminar boundary layer flow, appear to demonstrate a general upward shift of the j-factor curve due to increasing angle of attack. 2.5.1 Applicability to Solar Collectors The convecting surface surrounded by an insulating border is similar to the situation encountered when solar collectors are mounted on a roof. The results of the present work seem to indicate that when the boundary layer is laminar, the convection film coefficient for an angle of attack of 90° will be 1.3 times the coefficient for 0.007 0.006 90 Degree 0.005 60 Degree z-.z- ---,-----,..- -,-, -, --- -- . ---_ ---__ -- 0.004 II 0.003 Oil 1111r, ill ere Degree 111q11111 45 Deg-ee ill30 0.002 20,000 30,000 40,000 80,000 60,000 Reynolds Number D gre 100,000 MEASURED J-FACTOR DEPENDENCE UPON ANGLE OF ATTACK Figure 17 150,000 200,000 47 an angle of attack of 30°. This can be applied to a typical solar collector, as Sparrow [2] has done, which is 2.4 m (8 ft) square and exposed to a wind velocity of 3 m/s (10 ft/sec). The Jurges equation 2 would predict a convection film coefficient of about 17.5 w/m °C (3.1 Btu/hr ft2°F) while the equation proposed by Sparrow would 2 yield a value of 6.15w/m2 °C (1.1 Btu/hr ft °F). The present work yields a value of 5.78 w/m2°C (1.02 Btu/hr ft2°F) for an angle of at2 2 tack of 30 degrees and a value of 7.34 w/m °C (1.29 Btu/hr ft °F) for an angle of attack of 90 degrees. The results also suggest that the existence of a turbulent boun- dary layer can increase the convection film coefficient in the above example to 11.08 win°C (1.95 Btu/hr ft2°F), or 1.9 times the laminar boundary layer coefficient for an angle of attack of 30 degrees. The present data, due to the slope of the j-factor curve, seems to indicate increasingly laminar flow at larger angles of attack, which confirms the findings of Sam [4]. This implies that steeper angles of attack can retard the development of a turbulent boundary layer and the associated higher convection film coefficients. It is important to note that the Reynolds number associated with the example in this section was 460,000 while the highest Reynolds number data measured in this investigation was 140,000. Reynolds number measured by Sparrow and Tien was 100,000. sary extrapolation of the data should be kept in mind. The highest The neces- 48 SECTION III EXTENDING THE CONVECTION FILM COEFFICIENT DETERMINED FOR CONSTANT VELOCITIES TO RANDOM VELOCITY DISTRIBUTIONS, AN APPROXIMATE ANALYTICAL APPROACH 49 An accurate prediction of the convection film coefficient which a real system experiences is dependent on three factors. The first consideration is an accurate prediction of the dependence of the convection film coefficient on velocity of the wind, which was investigated in Section II. The second variable expresses the effect of the random variations of the velocity on the prediction of a time- averaged convection film coefficient, which will be considered in this section. The final consideration takes into account the random directional orientation of the wind relative to the heat transfer surface. More data are required in this area before accurate predictions can be made. The geometry of the heat transfer surface and all sur- rounding objects can have an effect on the ultimate directional orientation of the wind. This problem becomes immensely complex and is left to future study. 3.1 EVALUATING THE CONVECTION FILM COEFFICIENT USING THE AVERAGE AND THE STANDARD DEVIATION OF THE WIND VELOCITY The nature of the predicting equation for the convection film coefficient demonstrates a nonlinear dependence on wind velocity. If the convection film coefficient were dependent on the velocity in a strictly linear manner, then the average ambient wind velocity could be used to calculate the time-averaged convection film coefficient exactly. The rate at which the convection film coefficient increases with wind velocity decreases at higher and higher velocities. Consequently, simply using the average ambient wind speed in predicting the time- 50 averaged convection film coefficient will result in an error by not taking the distribution of wind velocity into account. The goal of this section is to predict the time-averaged convection film coefficient hw exactly with only V and a known for the velocity distribution. It is important to note that "exact only means that no error will be introduced due to the random nature of the wind velocity distribution. The method developed requires a convection film coefficient predicting equation in the form of a second order This polynomial would polynomial over a fixed range of velocities. appear as equation (3-1). hw(t) = a. + Where h w + a2V(t) 2 (3-1) represents the convection film coefficient due to the ambi- ent wind, V(t) is the ambient wind velocity as a function of time, and the coefficients a,, al, and a2 are known constants. The time- averaged convection film coefficient is defined to be equation (3-2). Substitution of equation (3-1) into equation (3-2) results in equation (3-3). jr hw = hwmdt (3-2) Fig = t jr (a0 + W.1(0 + a2V(t)2)dt (3-3) Carrying out the integration indicated in equation (3-3) using integration by parts yields equation (3-4) . hw = 1 jr a.dt + 1 TfaiV(t)dt + 1 2 "la V(t) dt I 2 (3-4) 51 Bringing the constants through the integral sign yields equation (3-5). 1 w 1 V(t)dt (t)dt + az aol f dt + alt = t f V(t) 2dt (3-5) Equation (3-5) represents thenexaceconvection film coefficient as a function of the velocity. The exact velocity distribution with re- spect to time must be known to evaluate equation (3-5) directly. The requirement of knowing the true velocity distribution can be replaced by knowing the average and standard deviation of the velocity distribution. Several definitions are required to perform the transformaThe time-averaged velocity can be expressed by equation (3-6). tion. V = (3-6) tf V(t)dt The statistical variance of the velocity is defined by equation (3-7). 2 S 1 = t f (V(t) (3-7) - V)2dt Where the square root of the variance is defined to be the standard deviation a, as in equation (3-8). a = iN/ST (3-8) Inspection of equation (3-5) reveals that the second integral on the RHS is simply the time-averaged wind velocity V, equation (3-6), and the first integral equals one. Carrying out the indicated simplifi- cations and placing brackets around the remaining integral yields equation (3-9). 52 = a, + aiV+ a2lf V(t)2dt (3-9) The remaining integral in equation (3-9) can be simplified by expanding equation (3-7). This expansion is performed in two steps shown in equation (3-10) and (3-11). 1 -f S2 S 2 = Jr 1 jr (v(t) - v) 2 (V(t) 2 (3-10) -2 - 2VV(t) + V )dt (3-11) Carrying out the indicated integration through equation (3-11) yields equation (3-12). S2 = t jrv(t)2dt r 2VV(t)dt + t j f V2dt (3-12) The last two terms on the RHS can be simplified by noting that V is a constant. The resulting simplification yields equation (3-13). 2V1jr V(t)dt + Vitfdt S2 = -r-lfV(t)2dt - (3-13) The second integral on the. RHS of equation (3-13) is simply V while The resulting simplification yields equa- the third integral is one. tion (3-14). s2 f V(t)2dt - 2V2 + V2 (3-14) Rearranging of equation (3-14) yields equation (3-15). 71t-fV(t)2dt = S2 + 1/2 (3-15) Equation (3-15) defines the remaining integral in equation (3-9). 53 Substitution of equation (3-15) into equation (3-9) will yield equation (3-16). (3-16) = a. + aiV + a2(S2 + V2) It is obvious from the form of equation (3-16) that the error introduced when evaluating a second order approximation of the timeaveraged convection film coefficient by simply using the average velocity is equal to the magnitude of the coefficient a2 times the variance of the velocity distribution. Equation (3-16) can also be rewritten in the form of equation (3-17). w I V = w 1 + a2S2 (.3 -17) V The magnifitude of a2 in equation (3-1) governs the degree of error introduced by using the average wind velocity in calculating the convection film coefficient. This was demonstrated in equation (3-17), since the convection film coefficient calculated at'the average velocity V will be equal to the general convection film coefficient when the velocity is constant or 17,4 is linear. An indication of the magnitude of the error introduced by using the average wind velocity can be achieved by forming a second order interpolating polynomial for the appropriate convection film coefficient predicting equation, and applying the derived equations to a physically measured velocity distribution with a calculated average velocity and standard deviation. Comparison of the two results will yield the error which is attributed to the use of the average velocity approximation. This 54 can be demonstrated by considering the convection film coefficient predicting equation which was determined by Sparrow and Tien [2] Combining equation (3-13) and the and is shown in equation (3-18). definition of the j-factor for heat transfer shown in equation (2-1), along with the associated definitions of the Reynolds number, Stanton number, and Nusselt number shown in equations (3-19), (3-20) and (3-21), respectively, will yield a relationships for the average convection film coefficient which is shown in equation (3-22). The parameters used in equation (2-1) and equation (3-18) through (3-21) are defined in Appendix A. j = .931 Re j = StPr -1/2 2/3 = (3-18) Nu 1/3 (2-1) RePr (3-19) Re = St = Nu (3-20) RePr (3-21) Nu = = 144,01/2Pr1/3 .931 (3-22) 1/2 1/2 L Table 3 shows the values used for the various parameters to arrive at 2 2 equation (3-23) expressed in w/m °K (Btu/hr ft °F) with the velocity expressed in m/s (ft/sec) = 5.460/2 (IT = .9633V1/2) (3-23) 55 TABLE 3 VALUES USED FOR PARAMETERS IN EQUATION (3-22) Value Parameter 3.2 L .3048 m (1 ft) Pr .706 K 0.0268 w/m°K (0.0155 Btu/hr ft°F) v 1.653 x 10 -5 2 m /S (17.79 x 10 -5 2 ft /sec) EXAMINATION OF THE ERROR INTRODUCED BY USING THE AVERAGE WIND VELOCITY TO PREDICT THE AVERAGE CONVECTION FILM COEFFICIENT Equation (3-23) must be expressed in the form of a second order polynomial with constant coefficients before the results of equation (3-16) can be applied. The conversion can be accomplished in many ways, but one which is most applicable is the construction of a second order interpolating polynomial through three selected points. Three points of interest to this investigation might be the convection film coefficient observed for velocities of 0.6, 7.6, and 15.2 m/S (2, 25, and 50 ft/sec.). Table 4 lists the velocities and the asso- ciated convection film coefficients as calculated by equation (3-13) which results from applying the parameters shown in Table 3 to 56 The interpolating polynomial I(V) can be found by equation (3-22). placing a second order Lagrangian Polynomial through the three points listed in Table 4. TABLE 4 SELECTED POINTS Velocity m/s (ft/sec) hw w/m 2°C 4.23 (Btu/hr ft 2°F) (1.36) 0.6 (2 ) 7.6 (25) 15.0 (4.81) 15.2 (50) 21.3 (6.81) The steps involved in this polynomial generation are shown in equations (3-24), (3-25), and (3-26). I(V) = 1.36 ( V-25)(V-50) (2-2g)(2-50) + 4 8 (25-2 ) (25-5d) + 6.81(2:2 (.502 ) (3-24) I(V) = .001232 (V2 - 75V + 1250) - .008365 (V2 - 52V + 100) (3-25) + .005675 (V2 - 271, + 50) (3-26) I(V) = .98725 + .18936V - .001458V2 Equation (3-26) is one of many second order polynomials which approxi- mate Sparrows' and Tiens' convection film coefficient predicting equation between 2 and 50 ft/sec. Figure 18 shows the degree of correspondence between the approximate polynomial and the original equation. Therefore, in the region of velocities from 2 to 50 ft/sec, 57 34. ) (6.0 ) 28. ../ 3 [ (5.0 L) `'41E 22. 1 3?(4.0) . / // /_,__// / / / )7 ./( iti 5.46 V 1/2 .96725 + .18936V - .0)1458V 2 / //e///./ 4 5.7 (1.0) ) (10) 3.0 (20)6.1 (30)9.1 Velocity (ft/sec) (40)12.2 m/s AGREEMENT BETWEEN INTERPOLATING POLYNOMIAL AND GOVERNING EQUATION (3-23) Figure 18 (cn) 15.2 58 the convection film coefficient as predicted by Sparrow [2] can be approximated by the second order polynomial I(V), as shown in equation (3-27). F (3-27) = .98725 + .18936V - .001458V2 The error introduced by using the average wind velocity to calculate the convection film coefficient may be evaluated by applying the results of equation (3-16) to equation (3-27). Necessary wind velocity data were recorded by the reactor building monitor at Oregon State University on November 29 and 30, 1978, and is tabulated in Appendix E. The convection film coefficient was evaluated for two separate cases. Case 1 used the average wind velocity to predict the convection film coefficient for November 29 and 30, 1978 as shown in equation (3-28). Case 2 used the average and standard deviation of the wind velocity on November 29 and 30 to predict the convection film coefficient using the results of equation (3-16) as shown in equation (3-29). (3-28) .001458V2 Case 1 71 = .98725 + .18936V Case 2 T1 = .98725 + .18936V - .001458 (S2 + V2) - (3-29) The results of this illustration are shown in Table 5. TABLE 5 ERRORS INTRODUCED BY IGNORING STATISTICAL INFORMATION Calculated h Btu/hr ft2°F Velocity Data ft/sec V a Case 1 Case 2 14.23 8.90 3.386 3.271 % change Date 11/29-30/78 3.4% 59 This example shows that the dependence of the convection film coefficient on the variation in velocity is relatively small for this particular situation. However, it also shows that due to the decreas- ing nature of the convection film coefficient prediction equation, the use of an average velocity will always over-predict the average heat loss. 60 SECTION IV CONCLUSIONS 61 CONCLUSIONS 4.1 DEPENDENCE OF THE CONVECTION FILM COEFFICIENT UPON ANGLE OF ATTACK The investigation observed flows ranging from laminar, as the slope of the j-factor curves seemed to indicate, at angles of attack of 30, 60, and 90 degrees, to turbulent, as the slope of the j-factor curve seemed to indicate, at angles of attack of zero and 45 degrees. The describing equation for laminar flow of 30 degrees was found to be represented by equation (4-1). (4-1) j = 0.876 Re-1/2 The describing equation for laminar flow at 90 degrees was thought to be represented by equation (4-2). (4-2) j = 1.114 Re-1/2 The describing equation for laminar flow of 60 degrees should have a multiplier which lies between 0.876 and 1.114 and will probably be closer to the higher value. The turbulent flow which was observed at angles of attack of zero and 45 degrees resulted in a j-factor curve described by equation (4-3) for both cases. j = .0335 Re -0.2 (4-3) Equations (4-1) and (4-2) indicate a measured dependence of the 62 convection film coefficient upon angle of attack which is beyond the expected experimental error. These results are in disagreement with the previous work of Sparrow and Tien [2][3] which indicate that the equation j = 0.931 Re -1/2 should apply for all angles of attack. It is the author's opinion that the disagreement is probably due to the differences in the air flow by the test surface. Sparrow and Tien used a 7.6 cm (3 in) square test surface inside a 30 x 60 cm (12 x 24 in) wind tunnel. In contrast, the present study used a 58.4 cm square surface in front of a 25.4 x 43.2 cm (10 x 17 in) wind tunnel exhaust nozzle. The flow experienced by Sparrow and Tien was three-dimensional while the flow in the present study was more or less two-dimensional. The results at a 90-degree angle of attack agree with previous work reported in Kays [5] for the corresponding laminar boundary layer wedge flow. The results also seemed to indicate that steeper angles of attack increased the tendency toward a laminar boundary layer. with recent findings by Sam, Lessmann, and Test [4]. This agrees 63 4.2 RANDOM WIND VELOCITIES AND THE AVERAGE CONVECTION FILM COEFFICIENT The results indicate that if statistical knowledge of the wind velocity distribution in the form of an average velocity and a standard deviatioh a were available, then a second order constant coefficient poly- nomial approximation of the convection film coefficient defining equation can yield results which account for the random nature of Equation (4-4) describes the form of the poly- the wind velocity. nomial expression for the convection film coefficient, and equation (4-5) describes the interaction of the statistical information which accounts for the random nature of the wind velocity. h h w w = a. + a1V(t) + a2V(t) = a. + 2 I, + a2(V2 + a 2 ) (4-4) (4-5) From the form of equation (4-5), it is obvious that the magnitude of the error encountered by using the average velocity only in equation (4-4) will be a2a 2 . Since the coefficient a2 is always negative in a convection film coefficient predicting equation, the error encountered will tend to overpredict the convection film coefficient. How- ever, the magnitude of the error was found to be less than 4% in the example provided. Therefore, the random nature of the wind velocity can probably be ignored in most cases. The effect of random wind directions was not considered in the present investigation. The variation of the convection film 64 coefficient with angle of attack, which was observed in Section II, indicates that changes in directional orientation of the wind could affect the total average convection coefficient. This is because a change in directional orientation of the wind effectively changes the angle of attack relative to the stationary structure. 65 4.3 FUTURE RESEARCH The results of the two-dimensional heat transfer studies currently under way, which the work of Sam, Lessmann, and Test [4] has contributed to, should provide information which is directly applicable to the results of this report. Future research should utilize a thermal decay method, such as the one employed here, in a three-dimensional flow such as was used by Sparrow and Tien [2][3]. This should confirm the author's opinion that the results obtained here which disagree with the results of Sparrow are the consequences of the differences between the two- and three-dimensional flows. 66 BIBLIOGRAPHY 1. Dr. Ing-Walter ()Urges, Der nrmeUbergang an einer ebenen Wand, Biehefte Zum Gesundheits-Ingenieur, Reihe 1, Beiheft 19, November 1924. 2. E. M. Sparrow and K. K. Tien, Forced Convection on an inclined and yawed flat plate - Application to Solar collectors, J. Heat Transfer 99, 507-512 (1977). 3. K. K. Tien and E. M. Sparrow, Local heat transfer and fluid flow characteristics for airflow oblique or normal to a square plate, Int. J. Heat Mass Transfer, Vol. 22, No. 3-A, pp. 349360 4. 1979). R. G. Sam, R. C. Lessmann, and F. L. Test, An experimental study of flow over a Rectangular Body, Journal of Fluids Engineering, Transactions of the ASME, Volume 101, December 1979, pp. 443448. 5. W. M. Kays, Convective Heat and Mass Transfer, New York: McGrawHill Book Company, 1966, pp. 203-243. 67 APPENDICES 68 APPENDIX A NOMENCLATURE A surface area of the convecting surface a arbitrary constant (with subscripts) H total thermal convection rate h local convection film coefficient h w convection film coefficient due to wind average convection film coefficient time average convection film coefficient due to wind j-factor K total thermal conductance loss K' thermal conductivity of the air k thermal conductivity k' mass transfer coefficient L length t characteristic length m mass of the aluminum plate used in apparatus m mass transfer rate Nu Nusselt number Pr Prandtl number Sc Schmidt number St Stanton number S 2 Statistical variance T temperature Te start temperature 69 Tm ambient temperature t time free stream wind velocity V average velocity of wind throughout time V(t) velocity of wind as a function of time volume of the aluminum plate used in apparatus kinematic viscosity of air p density of aluminum p' density of air pnw wall napthalene vapor concentration prim free stream napthalene vapor concentration standard deviation 70 APPENDIX B DETERMINATION OF STABLE TEMPERATURE DECAY REGION (Sphere Tests) During the course of this investigation, a dependence of the convection film coefficient upon plate temperature was observed. This caused concern for the validity of the techniques employed. An investigation determined the temperature region over which valid data could be obtained. The measured temperature dependence of the flat plate convection film coefficient is shown in Figure 19. is broken into three temperature regions. The temperature scale A plate temperature above 49°C exhibits a steeper slope mainly due to increasing insulation losses at higher temperatures. The slope of the curve in the region of 49 to 38°C is mainly due to temperature dependent properties of the aluminum plate and the air. The sharply decreasing slope between 38°C and ambient is thought to be due to the increasingly invalid assumption of a uniform body temperature and conduction resistance between the thermocouple and the body. The existence of the lower temperature boundary was confirmed by running identical tests on a 2.54 cm (1 in) diameter copper sphere suspended in the wind tunnel air stream by a thermocouple which was soldered in a hole drilled into the geometric center of the sphere. This arrangement eliminated contributions due to insulation losses. Figure 20 shows a graphical representation of the measured convection 71 34.0 (6) 28.4 (5) 22.7 0,1E (4) Increasin ) insulation 1 1..'= DSS Vow Measurement (Measurement errors 11.3 (2) 5.7 (1) 0 (175)79 (100)38 Plate Temperature(°F) °C (150)66 (125)52 MEASURED TEMPERATURE DEPENDENCE OF THE FLAT PLATE CONVECTION FILM COEFFICIENT Figure 19 (75)24 72 51.0 (9) 45.4 (8) (..)39.7 NE ) 3: 34.0 c (6) +- 28.4 ) 22.7 =c= U iifc rm T emperatu re (4) A ssumpti on I (valid kr:17.0 (3) 11.3 (2) 5.7 (1) 0 (200) (180) (160) (140) (120) (100) (80) 93 82 71 60 49 38 27 Sphere Temperature (°F) °C MEASURED TEMPERATURE DEPENDENCE OF THE SPHERE CONVECTION FILM COEFFICIENT Figure 20 73 film coefficient as a function of sphere temperature. The temperature region in which the uniform body temperature assumption is invalid for the sphere is shown in Figure 20. Due to the error encountered at the near ambient temperatures, the data for the flat plate were evaluated in the temperature region of 49 to 38°C. The lower limit of 38°C allows adequate time for re- producible results and avoids the measurement errors associated with lower plate temperatures. 74 APPENDIX C DETERMINATION OF INSULATION LOSSES The thermal loss through the insulation block must be known as accurately as possible to assure maximum system accuracy. A tech- nique was developed to measure the conduction losses as a function of plate temperature. This involved warming the aluminum plate to 121°C (250°F) and covering the aluminum plate and the upper surface of the insulation block with a second insulation block of identical construction. ent. The temperature decay was monitored from 121°C to ambi- The resulting conduction loss profile was examined to determine the best possible temperature region for data collection. The mathematical equations which describe the situation are the same as those developed in Section 2.4.1, with the exception of the elimination of convection losses. The resulting equation is shown in equation (A-1) where K represents the total conduction losses for both insulation blocks. me to (A-1) T0-c1.1 The value of K used in the data reduction is therefore equal to onehalf of the total conduction loss measured. The measured decay times, temperatures, and resulting calculated conductance rates for the double insulation block assembly are shown in Table 6. The cal- culated conductance for the single insulation block apparatus used in the experimental arrangement is shown in Table 7, and is graphically shown in Figure 21. 75 TABLE 6 MEASURED DECAY TIMES AND CALCULATED CONDUCTANCE LOSSES Calculated conductance Btu/hr°F (two insulation blocks) To, T min start ambient stop 5 213.7 70.4 203.1 0.475 8 203.1 70.3 190.0 0.398 6 190.0 70.4 181.9 0.364 10 181.9 70.5 170.6 0.330 10 170.6 70.7 161.4 0.298 14 161.4 70.7 150.6 0.278 16 150.6 70.7 140.7 0.255 21 140.7 70.7 130.2 0.255 20 130.2 70.8 121.9 0.230 35 121.9 70.6 110.9 0.213 50 110.9 70.2 99.3 0.207 55 99.3 70.0 90.4 0.203 105 90.4 69.9 80.3 0.200 To t 76 _. . TABLE 7 TOTAL MEASURED CONDUCTION LOSS THROUGH INSULATION BLOCK ASSEMBLY Temperature °C (°F) Energy loss w/°C (Btu/hr °F) 98 (208) .412 (.238) 91 (196) .344 (.199) 86 (186) .315 (.182) 80 (176) .285 (.165) 74 (165) .257 (.149) 68 (155) .239 (.138) 63 (145) .219 (.127) 57 (135) .208 (.120) 52 (126) .199 (.115) 47 (116) .183 (.106) 41 (105) .178 (.103) 35 ( 95) .176 (.102) 0.13 (0.25) 0.11 (0.20) -41( )100-1 Data Collection Temperature Bard 0.08 (0.15) Apparatus Conductance W/°C (BTU/hr', F) 0.05 (0.10) 0 (90)32 (110)43 (130)54 (150)66 (170)78 Temperature(°F) °C (190)88 TOTAL INSULATION BLOCK ASSEMBLY THERMAL CONDUCTANCE AS A FUNCTION OF PLATE TEMPERATURE Figure 21 (210)99 78 APPENDIX D TABULATED DATA AND RESULTS 79 TABLE 8 MEASURED DATA u Temperatures °F T, To t oo ft/sec 6.33 7.00 9.43 11.16 11.93 13.34 17.39 17.64 22.42 23.60 24.95 24.75 24.32 7.89 10.75 11.74 23.95 23.58 min 8 6 6 5 5 4 4 4 4 4 3 3 3 8 5 6 3 23.95 7.89 4 4 4 4 8 12.11 5 13.50 18.02 5 21.51 16.87 21.61 23.77 5.58 10.54 11.93 13.83 18.02 21.40 23.67 5.58 5.96 11.93 13.66 17.26 23.86 21.70 4 4 4 6 5 5 5 4 4 3 6 6 5 5 4 3 4 . 123.4 121.8 70.8 71.3 123.1 72.1 119.3 119.1 124.0 119.0 118.8 122.3 125.2 121.5 122.0 123.9 124.3 120.3 121.5 119.6 124.8 119.3 119.6 119.6 121.5 119.5 123.0 125.0 120.9 118.6 122.8 121.4 120.7 124.3 119.3 120.5 119.3 123.9 121.5 120.0 123.6 123.5 121.5 120.6 71.7 72.1 70.9 71.8 71.7 71.5 72.2 72.2 71.3 73.1 71.7 70.7 71.3 71.4 72.5 71.9 71.6 71.6 72.0 70.8 71.1 70.4 71.7 71.7 71.8 71.7 71.8 71.8 71.2 72.2 72.1 71.1 72.7 71.5 71.7 71.3 72.1 71.5 T angle of attack 100.5 103.7 100.2 99.3 99.0 102.6 97.7 97.2 96.6 97.5 100.0 99.6 101.9 99.8 101.3 99.3 101.7 101.3 98.5 101.0 97.8 zero ° 97.1 45° 99.0 99.4 99.8 97.7 94.9 100.8 98.5 98.1 98.9 96.8 95.8 99.0 100.9 99.5 96.7 97.4 97.6 99.4 94.4 H H II H tI H it Hi H H II H 30° H H H H H H H H H II H 60° H H H II H H 90° II H H H H H 80 TABLE 9 CALCULATED J-FACTORS wind velocity Reynolds # j-factor 6.33 7.00 9.43 11.16 11.93 13.34 17.39 17.64 22.42 23.60 24.95 24.75 24.32 7.89 10.75 11.74 13.34 23.95 23.58 21.51 16.87 23.95 7.89 12.11 13.50 18.02 36200 40000 53900 63800 68200 76300 99400 100900 128200 135000 142700 141500 139000 45100 61500 67100 76300 137000 135000 123000 96500 137000 45000 69000 77000 103000 124000 135000 31900 60300 68200 79100 103000 122000 135000 31900 34100 68200 78100 98700 136000 124000 0.00421 0.00395 0.00398 0.00370 0.00355 0.00368 0.00330 0.00333 0.00302 0.00301 0.00294 0.00302 0.00299 0.00372 0.00340 0.00313 0.00311 0.00248 0.00242 0.00257 0.00277 0.00242 0.00405 0.00343 0.00342 0.00329 0.00283 0.00284 0.00637 0.00447 0.00396 0.00365 0.00335 0.00322 0.00305 0.00646 0.00634 0.00419 0.00393 0.00381 0.00319 0.00338 21.61 23.77 5.58 10.54 11.93 13.83 18.02 21.40 23.67 5.58 5.96 11.93 13.66 17.26 23.86 21.70 angle of attack zero attack 30° 45° 60° 90° 81 APPENDIX E TABLES, CHARTS, AND GRAPHS 82 TABLE 10 BIOT NUMBERS FOR VARIOUS MATERIALS Assumptions 2 h = 19 w/m °C Q = 0.00406 m k w/m°k Biot Number pure copper 377 0.00020 pure aluminum 205 0.00037 (; aluminum alloy 7075 T6 Alcladv=I 131 0.00058 Material pure iron 63 0.0012 83 18.3 ( 60) . / / rate Flow 1416 ( 000) 1180 15.2 (50) ( 500) . 0 E12.2 "a(40) .L. (2000) 4J a) Exit 4) -rn'-Velocity 9.1 (8(30) 4-2 707 500) g 47 1.7( LA.1 472 6.1 (20) I 000) 3.0 (10) 235 (500) Design Exit Are. 0 0 (1)0.09 (3)0.28 (2)0.19 Exit Area (ft2) m2 FAN PERFORMANCE Figure 22 84 TABLE 11 PROPERTIES OF THE ALUMINUM PLATE Alloy 7075 Alclad Temper T6 Thickness .406 cm (.160 in) Surface condition As rolled Density 2794 kg/m Specific heat 962 j/kg°k (.230 Btu/lb°F) @ 100°C 3 (174 lb/ft 3 ) 870 j/kg°k (.208 Btu/lb°F) @ 0°C Thermal conductivity 131 w/m°k (76 Btu/hr ft°F) @ 25°C Taken from Strength of Metal Aircraft Elements, MIL-HDBK-5. 85 TABLE 12 PROPERTIES OF INSULATION BLOCK MATERIAL (manufacturer specification) Manufacturer Polymer Building Systems, Inc. 6918 Gage Street Riverside, California 92504 Product name PBS 800-L75 Insulation material closed cell rigid urethane Thermal conductivity as specified .12 - Density 2 lb/ft Service temperature -73°C to +121°C (-100°F to 250°F) R value 3.57 per half-inch thick sheet .14 Btu/hr ft2°F/in 3 0.09 (0.3) Measurement Uncertainty m/s 0.06 (0.2) (ft/sec) 0.03 (0.1) 0 0 1.5(5) 3.0(10) 4.5(15) 6.1(20) Measured air stream velocity(ft/sec) m/s WIND VELOCITY MEASUREMENT UNCERTAINTY Figure 23 7.6(25) 87 TABLE 13 WIND VELOCITY DATA Oregon State University Reactor Building velocity measured in miles per hour November 29, 1978 -time speed 8:10 1 15 20 25 30 35 40 45 50 55 1 9:00 05 10 15 20 25 30 35 time 11:00 05 10 15 20 25 30 35 2 2 1 1 2 1 0 0 0 0 .5 speed time speed 3.5 3.5 2:00 10 10 10 10 10 12 3 3 3 3 2 2 40 3 45 50 55 3 12:00 4 4 4 3 4 10:00 2 05 10 15 20 25 30 35 40 45 50 55 05 10 15 2 3 1:00 7 20 25 30 2 8 8 8 10 35 2 40 45 50 2 2 05 10 15 20 25 30 35 3 40 55 3 45 50 55 1 1 2 2 1.5 40 1 45 50 55 3 3 3 3 1 1 4.5 5 5 5 5 5.5 6 6.2 6.5 11 11 10 12 10 11 10 05 10 15 20 25 30 35 40 45 50 55 12 13 13 13 13.5 12 3:00 11 05 10 15 12 20 25 30 35 40 45 50 55 11 11 12 11 11 12 12 12 10 10 4:00 9 05 10 15 20 11 9 9 8 88 Table 13, continued -- November 30, 1978 -time speed time 8:05 2.5 2.6 2.6 2.5 3.6 11:00 10 15 20 25 30 35 40 45 50 55 5.1 7.0 8.0 7.5 12 12.5 20 25 30 35 40 45 50 10 8.2 8.2 11.5 11.2 12.5 11.0 11.2 10 10 55 11 10:00 10 9:00 05 15 05 10 15 20 25 30 35 40 45 50 55 speed 16 05 10 15 20 25 30 35 40 45 50 55 15.5 16 12:00 20 19 20 16.2 05 10 15 20 25 30 35 40 45 50 55 15 16 16.2 16.2 19 19 20 20 20 21 22 20 20 20 20 23 20 time seed 2:00 7 05 10 15 20 25 30 35 40 45 50 55 3:00 6.5 9 12 12 11 10 10.5 9 6.5 7.5 10 9 05 9 10 16 16 15 12 15 18 15 20 25 30 35 40 45 50 21 15 17 12.5 14 12.5 15 13 15 15 12.5 12.5 15 16 1:00 05 10 15 20 25 30 35 40 45 50 55 19.5 20 20 20 19 19 16.2 20 17 16 14 10 Statistical Analysis V = 14.23 ft/sec a = 8.90 ft/sec